JP2023141214A - Manufacturing method of decorative sheet and decorative sheet - Google Patents

Abstract

To provide a manufacturing method of a decorative sheet having texture more close to a genuine object and having excellent designability.SOLUTION: A manufacturing method of a decorative sheet includes the steps of laminating a pattern layer 5, a transparent thermoplastic resin layer 6, and a surface protective layer 7 in this order on one side of a colored thermoplastic resin layer 2 (FIG. 2(a)), forming a pattern layer 8a made of a gross matte developing pattern unit 3 that synchronizes with the pattern of the pattern layer 5, by utilizing a material containing a Japanese ink having light absorption to infrared ray more than the colored thermoplastic layer 2 on the other surface of the colored thermoplastic resin layer 2 (FIG. 2(b)), irradiating the layer with infrared rays (FIG. 2(d)), and after irradiation with infrared rays, stamping an embossing plate for forming an embossed shape on the surface protective layer 7 (FIG. 2(e)).SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for manufacturing a decorative sheet and a decorative sheet.

Decorative sheets were developed and evolved during the development of residential construction as an industry. Originally, houses used materials such as wood and stone that matched the characteristics of the region, but as the housing industry developed and industrialization progressed, there was a shift from natural materials to artificial materials. Furthermore, in recent years, the heavy use of high-quality wood and stone may lead to deforestation and environmental problems, which has become a factor in increasing demand for decorative sheets. For example, decorative materials such as plywood, MDF (medium density fiber board), particle board, and other wood base materials, resin base materials, inorganic noncombustible base materials, metal base materials, etc., with decorative sheets pasted on them are widely used (e.g. , see Patent Document 1).
Furthermore, the design of decorative sheets often imitates the surface of wood, stone, or the like.

Patent No. 5045180

By the way, compared to real wood, stone, etc., decorative sheets tend to have a flat surface texture. Actual wood and stone have unevenness and texture that differ from place to place due to differences in surface material and structure. Areas with different textures often have different colors, but this is not expressed in decorative sheets, and the expensive real ones are much superior in terms of design.

The present invention has been made in view of the above points, and an object of the present invention is to provide a method for manufacturing a decorative sheet and a decorative sheet having a more realistic texture and excellent design.

In order to solve the above problems, one aspect of the present invention is a method for manufacturing a decorative sheet having an embossed shape that matches a pattern, in which a pattern layer, a transparent resin layer and a surface protection layer are formed on one side of a colored resin layer. A process of laminating the layers in this order, and forming a pattern layer on the other side of the colored resin layer that synchronizes with the pattern by using a predetermined material that is more absorbent than the colored resin layer for light of a predetermined wavelength. After the step of forming, the step of irradiating with irradiation light in which the power of light of a predetermined wavelength is stronger than the power of light of other wavelengths, and the step of irradiating with irradiation light, an embossing plate for forming an embossed shape is applied to the surface protective layer. Provided is a method for manufacturing a decorative sheet, comprising: a step of stamping a decorative sheet.

Another aspect of the present invention is a decorative sheet having a pattern layer, wherein the pattern layer, the transparent resin layer, and the surface protection layer are laminated in this order on one side of the colored resin layer, and the other side of the colored resin layer is laminated in this order. A pattern layer laminated on the surface, in which a predetermined material having a light absorbing property for light of a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern of the pattern layer, and a surface protective layer, in plan view. Embossed portions are formed at positions that overlap with portions formed of a predetermined material, thereby providing a decorative sheet.

According to one aspect of the present invention, it is possible to obtain a decorative sheet that has a texture close to that of the surface of wood, stone, etc. used as building materials, and has an excellent design.

FIG. 1 is a cross-sectional view schematically showing an example of a decorative sheet produced by a method for manufacturing a decorative sheet according to an embodiment of the present invention. FIG. 1 is a process diagram schematically showing an example of a procedure for producing a decorative sheet according to an embodiment of the present invention.

Embodiments of the present technology will be described below with reference to the drawings. In this embodiment, decorative sheets and decorative materials for floors or fittings will be exemplified and explained, but decorative sheets used for other parts may also be used.
Here, the drawings are schematic, and the relationship between thickness and planar dimension, the ratio of the thickness of each layer, etc. differ from the actual one. Further, the embodiments shown below illustrate configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is that the materials, shapes, structures, etc. of the component parts are It is not specific to anything. The technical idea of the present invention can be modified in various ways within the technical scope defined by the claims.

A method for manufacturing a decorative sheet according to an embodiment of the present invention is a method for manufacturing a decorative sheet having an embossed shape that matches a pattern, in which a pattern layer, a transparent resin layer and a surface protection layer are formed on one side of a colored resin layer. layers in this order, and using a predetermined material on the other side of the colored resin layer that is more absorbent than the colored resin layer for light of a predetermined wavelength to synchronize with the pattern. The step of forming a pattern layer, the step of irradiating the irradiation light with the power of the light of the predetermined wavelength stronger than the power of the light of other wavelengths, and the step of irradiating the irradiation light, the surface protective layer is coated with the This is a method for manufacturing a decorative sheet, comprising the steps of pressing an embossing plate for forming an embossed shape.

Further, a decorative sheet according to another embodiment of the present invention is a decorative sheet having a pattern layer, which includes a pattern layer, a transparent resin layer, and a surface protection layer laminated in this order on one side of the colored resin layer; a pattern layer laminated on the other surface of the colored resin layer, in which a predetermined material having a light absorption property for light of a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern of the pattern layer; The decorative sheet is provided with an embossed portion formed at a position of the surface protective layer that overlaps a portion formed of the predetermined material in a plan view.

A decorative sheet 1 formed by the method for manufacturing a decorative sheet according to an embodiment of the present invention includes, for example, a colored thermoplastic resin layer 2, a pattern layer 5, and a transparent thermoplastic resin layer (a transparent A resin layer) 6 and a surface protection layer 7 are laminated in this order, and the surface protection layer 7 has an embossed portion (embossed shape) 7a formed therein. Further, on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5, a pattern layer 8a consisting of the pattern portion 3 for producing gloss matte and a primer layer 8 are formed.

[Colored thermoplastic resin layer]
The colored thermoplastic resin layer 2 as a base material is made of, for example, polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer. Examples include polymers, ethylene-acrylic ester copolymers, ionomers, acrylic esters, and methacrylic esters. Among these, polyolefin resins are preferably used in terms of environmental compatibility, processability, and cost. The grade and composition of the resin can also be selected in consideration of ease of sheeting, printability, and suitability for bending.

For the colored thermoplastic resin layer 2, the hue can be appropriately selected as the base color of the pattern layer 5. The colored thermoplastic resin layer 2 can be colored by, for example, mixing and kneading a coloring agent such as a pigment when sheeting the thermoplastic resin. Alternatively, a colored layer may be provided as a solid ink layer by coating or printing before providing the pattern portion 3 for producing gloss matte.

[Picture layer]
The pattern layer 5 is a printed layer on which a pattern is printed to give the decorative sheet 1 a design. As a method for forming the pattern layer 5, a known printing method can be adopted. Although the printing method is not particularly limited, a gravure printing method is preferable in consideration of productivity and pattern quality. For example, if the colored thermoplastic resin layer 2 can be prepared in a rolled form, printing for forming the pattern layer 5 can be performed using a roll-to-roll printing device. In addition to these, examples of printing methods include offset printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, and transfer printing from a transfer sheet. When using such a printing method, the picture pattern of the picture layer 5 can be formed by multicolor printing using normal process colors of yellow, red, blue, and black, or by printing each color of the picture pattern. It can also be formed by preparing a plate and performing multicolor printing using special colors.

Further, as the pattern of the pattern layer 5, any pattern may be adopted in consideration of the designability as a floor material or fittings. For example, imagining a floor made of stone such as marble, the grain of the marble can be used as a pattern. For example, if the pattern is wood-based, various wood grains or cork can be used as the pattern. Furthermore, for example, in addition to the patterns of natural materials, artificial patterns such as artificial patterns and geometric patterns based on these motifs can also be used. In addition to these, other patterns include, for example, spring wood areas and fall wood areas in cross-sections of annual rings, wood grain patterns consisting of conduit parts, leather patterns, and stone surfaces such as marble, granite, and sandstone. Examples include stone grain patterns, sand grain patterns, tiling patterns, brickwork patterns, cloth patterns, geometric figures, letters, symbols, abstract patterns, flower patterns, landscapes, characters, etc.
Printing ink is a mixture of a solvent and solid components such as a colorant and a binder resin.

Examples of solvents include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, 2-ethoxyethyl acetate, etc. Ester organic solvents; Alcohol organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; Ketone organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; diethyl Examples include ether organic solvents such as ether, dioxane, and tetrahydrofuran; chlorine organic solvents such as dichloromethane, carbon tetrachloride, trichlorethylene, and tetrachloroethylene; and inorganic solvents such as water. One type of solvent may be used alone, or two or more types may be used in combination.

Examples of the binder resin include chlorine resin, urethane resin, acrylic urethane resin, acrylic resin, polyester resin, polyamide resin, butyral resin, polystyrene resin, nitrocellulose resin (nitrified cotton), cellulose acetate resin, and the like. Examples of chlorinated resins include polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, ethylene-vinyl chloride copolymer, vinyl chloride-vinyl acetate copolymer, and vinyl chloride-vinyl acetate-(meth)acrylic copolymer. Examples include polyvinyl chloride resins such as, polychlorinated propylene, and chlorinated polypropylene. Here, (meth)acrylic means acrylic or methacrylic. The binder resin may be used alone or in combination of two or more.

Examples of colorants include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, yellow lead, titanium yellow, Bengara, cadmium red, ultramarine, and cobalt blue; quinacridone red, and Examples include organic pigments such as indolinone yellow and phthalocyanine blue. One type of coloring agent may be used alone, or two or more types may be used in combination.
Here, the solvent contained in the printing ink eventually evaporates. Therefore, the pattern layer 5 is mainly formed of solid components such as colorants and binder resins.

The printing ink may also contain stabilizers, plasticizers, catalysts, curing agents, etc. as other components. As the printing ink, an ink suitable for the printing method may be used. In particular, it is preferable to select it in consideration of adhesion to the colored thermoplastic resin layer 2, printability, and weather resistance as flooring material or fittings. The thickness of the pattern layer 5 can be adjusted as appropriate in consideration of the decorativeness required for the pattern layer 5, the three-dimensional formability of the decorative sheet 1, and the like. The thickness of the pattern layer 5 is usually 1 μm or more and 1 mm or less, preferably 2 μm or more and 0.1 mm or less, and more preferably 2 μm or more and 50 μm or less.

For the purpose of improving the adhesiveness between the pattern layer 5 and the transparent thermoplastic resin layer 6, an adhesive layer (not shown) may be provided on the surface of the pattern layer 5 that is in contact with the transparent thermoplastic resin layer 6. By strengthening these bonds, the decorative sheet 1 can be given bendability that follows curved surfaces and right-angled surfaces. The resin used for the adhesive layer (not shown) is not particularly limited. For example, a two-component curable urethane resin can be used. Alternatively, the adhesive resin may be adhered to the pattern layer 5 using a urethane adhesive. For example, a coating device or a gravure printing device can be used to apply the resin used for the adhesive layer (not shown).

In addition, a glitter layer (not shown) may be provided between the pattern layer 5 and the transparent thermoplastic resin layer 6 for the purpose of suitably imparting design effects such as depth and brightness to the decorative sheet 1. good. The glitter layer (not shown) preferably contains a glitter pigment and a binder resin. Examples of bright pigments include pearl pigments and metal pigments. Particularly, pearl pigments are preferable because they can suppress a decrease in the light transmittance of the glitter layer and do not impair the visibility of the pattern layer 5.

Pearl pigments are pigments that can impart pearlescent luster. For example, the surface of base particles may be coated with a metal oxide. As the base particles, scaly particles such as mica are preferred. Examples of metal oxides include oxides of metals such as titanium, iron, zirconium, silicon, aluminum, and cerium. One type of metal oxide may be used alone, or two or more types may be used. Specific examples include titanium mica, titanium mica coated with iron oxide, titanium mica coated with iron oxide, titanium mica coated with navy blue, titanium mica coated with navy blue-iron oxide, titanium mica coated with chromium oxide, titanium mica coated with carmine, titanium mica coated with organic pigment, and titanium mica coated with organic pigment. Oxide-coated mica such as titanium-coated mica and titanium oxide-coated synthetic mica; Oxide-coated glass powder such as titanium oxide-coated glass powder and iron oxide-coated glass powder; Oxide-coated metal particles such as titanium oxide-coated aluminum powder; Basic Examples include scaly foil pieces of lead carbonate, lead hydrogen arsenate, bismuth oxide chloride, etc.; fish scale powder, shell pieces, pearl pieces, etc.

Examples of the metal pigment include pigments made of metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, gold powder, and silver, and alloys of these metals. One type of metal pigment may be used alone, or two or more types may be used in combination.
The average particle diameter of the glitter pigment is preferably 40 μm or less, and preferably 30 μm or less when forming a glitter layer using gravure printing, for example, from the viewpoint of imparting an excellent design effect. More preferred. From the same viewpoint, the ratio of [average particle diameter of glitter pigment/thickness of glitter layer] is preferably 0.01 or more and 15 or less, more preferably 0.5 or more and 10 or less. In addition, in this specification, the "average particle diameter" is a value that can be determined as the mass average value D50 in particle size distribution measurement by laser light diffraction method.

Further, examples of the binder resin include thermoplastic resins, cured products of curable resin compositions, etc., and cured products of curable resin compositions are preferred from the viewpoint of durability. Examples of the cured product of the curable resin composition include a cured product of a thermosetting resin composition and a cured product of an ionizing radiation curable resin composition. From the viewpoint of interlayer adhesion, a cured product of a thermosetting resin composition is preferred.
Thermosetting resin compositions used in the glitter layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, aminoalkyd resin compositions, melamine resin compositions, guanamine resin compositions, and urea resin compositions. and thermosetting acrylic resin compositions. These thermosetting resin compositions include monomers and/or prepolymers constituting each resin, and a curing agent added as necessary. As the ionizing radiation curable resin composition used for the glitter layer, the same ionizing radiation curable resin composition as the surface protective layer 7 described later can be used.

The content of the glitter pigment in the glitter layer is preferably 10 parts by mass or more and 90 parts by mass or less, more preferably 50 parts by mass or more and 80 parts by mass or less, based on 100 parts by mass of the binder resin. . By setting the content of the bright pigment to 10 parts by mass or more, a sufficient gloss can be imparted, and by setting the content to 90 parts by mass or less, it is possible to suppress the visibility of the pattern layer described below from being impaired. . From the same viewpoint, the thickness of the glitter layer is preferably 1 μm or more and 30 μm or less, more preferably 5 μm or more and 20 μm or less.

The glitter layer can be formed into any pattern depending on the desired design. Examples include wood grain patterns, leather patterns, stone grain patterns, sand grain patterns, tiling patterns, brickwork patterns, cloth grain patterns, geometric figures, letters, symbols, abstract patterns, flower patterns, landscapes, characters, and the like. Moreover, it is preferable that the arbitrary pattern has shading in order to further enhance the design effect. The shading may be formed by the size of the halftone dots or the thickness of the halftone dots, but it should be formed by the density of the halftone dots (in other words, the size of the halftone dots is uniform and the density of the halftone dots is used to form the shading). is preferred.
The glitter layer can be formed, for example, by using a coating liquid containing a glitter pigment and a binder resin using a general-purpose printing method such as gravure printing. In addition, when forming the density of the glittering layer from the density of the halftone dots, the halftone dots of the printing plate may be formed by an FM (frequency modulation) screen.

[Transparent thermoplastic resin layer]
The transparent thermoplastic resin layer 6 provides thickness and depth in terms of design, and also protects the pattern layer 5 and imparts good surface properties so that the weather resistance and abrasion resistance of the decorative sheet 1 are improved. This is a resin layer. As a material for the transparent thermoplastic resin layer 6, for example, vinyl chloride resin, acrylic resin, or polyolefin resin (polypropylene resin, polyethylene resin) can be used. In particular, polyolefin resins are preferred in consideration of environmental compatibility, processability, and cost. Further, the grade and composition of the resin can be selected in consideration of ease of sheeting, printability, and suitability for bending, in addition to environmental compatibility, processability, and price. With regard to suitability for bending, it is important to select a material that takes into account that no whitening or cracking will occur at the bent portion.
As a method for forming the transparent thermoplastic resin layer 6, a lamination method can be adopted. Further, for example, when forming the transparent thermoplastic resin layer 6 and the adhesive layer (not shown) at the same time, a method of co-extruding both layers at the same time can be adopted.

[Surface protective layer]
The surface protective layer 7 is a layer for imparting surface properties such as abrasion resistance to the decorative sheet 1. Further, the surface protective layer 7 is also a layer for adjusting the gloss of the surface of the decorative sheet 1. The surface protective layer 7 may be a single layer or a multilayer. For example, as the surface protection layer 7, two layers, a first surface protection layer (not shown) and a second surface protection layer (not shown), can be provided in this order on the transparent thermoplastic resin layer 6. When providing the surface protective layer 7 consisting of a first surface protective layer (not shown) and a second surface protective layer (not shown), each layer is coated using a known coating device or a known coating device depending on the type of curable resin. Coating and curing of the coating film may be performed using a heat drying device or an ionizing radiation irradiation device.
The surface protective layer 7 has a curable resin as a main component. That is, it is preferable that the resin component of the surface protective layer 7 is substantially composed of a curable resin. Substantial means, for example, 80 parts by mass or more when the entire resin is 100 parts by mass. The surface protective layer 7 may contain a weatherproofing agent, a plasticizer, a stabilizer, a filler, a dispersant, a coloring agent such as a dye or a pigment, a solvent, etc., as necessary.

As the material for the surface protection layer 7, for example, an ionizing radiation curing type resin or a two-component curing type urethane resin can be used. The ionizing radiation-curable resin is not particularly limited. For example, transparent resins whose main components are prepolymers (including oligomers) and/or monomers containing radically polymerizable double bonds in their molecules that can be polymerized and crosslinked by irradiation with ionizing radiation such as infrared rays, ultraviolet rays, and electron beams. can be adopted. These prepolymers or monomers can be used alone or in combination. Specifically, the prepolymer or monomer is a compound having a radically polymerizable unsaturated group such as a (meth)acryloyl group or a (meth)acryloyloxy group, or a cationically polymerizable functional group such as an epoxy group in the molecule. Can be mentioned. Also preferred is a polyene/thiol-based prepolymer made of a combination of polyene and polythiol. Here, the (meth)acryloyl group means an acryloyl group or a methacryloyl group.

Examples of prepolymers having radically polymerizable unsaturated groups include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, and silicone (meth)acrylate. etc. The molecular weight of these is preferably about 2,500,000 to 100,000.
Examples of monomers having a radically polymerizable unsaturated group include methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, phenoxyethyl (meth)acrylate, and the like as monofunctional monomers. Examples of polyfunctional monomers include diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra( Examples thereof include meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

Further, examples of the prepolymer having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol-type epoxy resins and novolac-type epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. .
Furthermore, examples of polyene-based prepolymers include those obtained by adding allyl alcohol to both ends of polyurethane made of diol and diisocyanate. Examples of thiol-based prepolymers include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

As the ionizing radiation, for example, electromagnetic waves or charged particles having energy capable of curing molecules in the ionizing radiation curable resin (composition) can be employed. Examples of the curing reaction include crosslinking curing reactions. Further, as the ultraviolet light source, for example, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, a metal halide lamp, etc. can be employed. The wavelength of the ultraviolet rays is preferably, for example, 190 nm or more and 380 nm or less. Further, as the electron beam source, for example, an electron beam accelerator such as a Cockcroft-Walton type, a Vandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, or a high frequency type can be adopted. Particularly preferred is one that can irradiate electrons with an energy of 100 keV or more and 1000 keV or less (more preferably electrons with an energy of 100 keV or more and 300 keV or less).

Furthermore, the two-component curable urethane resin is not particularly limited. For example, one containing a polyol component having an OH group as a main component and an isocyanate component as a curing agent component can be employed. Examples of polyol components having OH groups include acrylic polyols, polyester polyols, polyether polyols, and epoxy polyols. Further, examples of the isocyanate component include tolylene diisocyanate, hexamethylene diisocyanate, and metaxylene diisocyanate.

[Embossed part]
Embossed portions 7a having an uneven pattern are formed on the surface of the surface protective layer 7 in order to impart a certain design quality. Examples of the uneven pattern include wood grain board conduit grooves, stone plate surface unevenness (granite cleavage surface, etc.), fabric surface texture, satin finish, sand grain, hairline, and straight line grooves. The embossed portion 7a is provided so that its uneven pattern is in synchronization with the pattern of the pattern layer 5.
As a method for forming the uneven pattern, for example, embossing can be adopted. The embossing method is not particularly limited. For example, a known single-fed embossing machine or rotary embossing machine can be used.

[Handle for gloss matte appearance]
The gloss matte developing handle 3 is made of a material that absorbs light of a predetermined wavelength, such as a material that absorbs infrared rays. The pattern part 3 for producing gloss matte is formed of a material containing black ink containing carbon black, for example, formed of urethane-based printing ink. The pattern part 3 for producing gloss matte is arranged at a position that is in synchronization with the pattern of the pattern layer 5. For example, in the case of the pattern layer 5 having a wood grain pattern, the pattern portion 3 for producing gloss matte is formed at a position overlapping with the wood grain conduit groove of the pattern layer 5 in plan view. Note that the term "synchronized" as used herein means that the pattern part 3 for producing gloss matte and the pattern of the pattern layer 5 are formed at a position where they overlap in plan view.

The thickness of the pattern part 3 for producing gloss matte is such that the transparent thermoplastic resin layer 6 and the surface protection layer 7 can be softened to the extent that an uneven shape can be sufficiently formed on the surface protection layer 7 during the embossing process described below. It should be as thick as possible. In addition, in order to obtain a sufficient gloss matte effect, it is preferable that the difference in glossiness between the part where the pattern part 3 for producing gloss matte is formed and the part where it is not formed is 5 or more, that is, the image density level is It is preferably 60% or more.

[Light of specified wavelength]
As described above, the gloss matte developing handle portion 3 is formed of a material that has light absorption properties for light of a predetermined wavelength. Examples of the light having a predetermined wavelength include infrared rays, ultraviolet rays, visible light, electron beams, X-rays, and ion beams.
[Pattern layer]
The pattern layer 8a is formed on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5. The pattern layer 8a is composed only of the gloss matte pattern portion 3 made of a material that absorbs infrared rays, for example.

[Primer layer]
The primer layer 8 is a base layer and is a layer for improving the adhesion and corrosion resistance to a base material (not shown) to which the decorative sheet 1 is attached. The primer layer 8 is provided on the opposite side of the patterned layer 8a from the colored thermoplastic resin layer 2.
The primer layer 8 is formed using, for example, polyester resin, organic additives, pigments, and the like. The primer layer 8 may contain a rust preventive pigment for the purpose of improving corrosion resistance. The thickness of the primer layer 8 is, for example, in a range of 1 μm or more and 10 μm or less.

[Method for manufacturing decorative sheets]
Next, an example of a method for manufacturing a decorative sheet according to this embodiment will be described with reference to FIG. 2.
First, a colored thermoplastic resin layer 2 is formed. For example, it is formed using PBT (polybutylene terephthalate resin) and has a thickness of, for example, 50 μm (FIG. 2(a)).
Next, a pattern layer 5 is printed on the colored thermoplastic resin layer 2 using, for example, urethane-based printing ink, and a transparent thermoplastic resin layer 6 is formed on the pattern layer 5, for example, using PP (polypropylene) with a thickness of 38 μm. ) are stacked. Then, a surface protection layer 7 is laminated on the transparent thermoplastic resin layer 6.

Next, on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 5, a pattern portion 3 for producing gloss matte is formed, and a pattern layer 8a is formed. For example, using urethane-based black ink containing carbon black, the pattern portion 3 for producing gloss matte is formed at a predetermined position that is in sync with the pattern of the pattern layer 5 (FIG. 2(b)).
Next, a primer made of, for example, polyester resin is applied on the colored thermoplastic resin layer 2 including the gloss matte producing handles 3 so as to fill the gaps between the gloss matte producing handles 3 and to cover the upper surface thereof. Layer 8.
Next, the entire laminate in which these layers are laminated is irradiated with infrared rays (irradiation light) (FIG. 2(d)), and immediately after the infrared ray irradiation, an embossing plate such as an embossing roll is stamped on the surface of the surface protection layer 7. (Figure 2(e)). As a result, the embossed portion 7a is formed, and the decorative sheet 1 is formed.

Here, the pattern part 3 for producing gloss matte is formed of black ink having infrared absorption characteristics. Therefore, when the laminate is irradiated with infrared rays, the part of the surface protection layer 7 that overlaps with the pattern part 3 for producing gloss matte in plan view is more transparent than the part that does not overlap with the pattern part 3 for producing gloss matte. The plastic resin layer 6 and the surface protection layer 7 are easily softened. That is, after infrared irradiation, the transparent thermoplastic resin layer 6 and the surface protection layer 7 have a portion that is easy to soften and a portion that is difficult to soften. Therefore, when an embossing plate is pressed onto the transparent thermoplastic resin layer 6 and the surface protection layer 7 in this state, unevenness is likely to be formed in the softened portions, and unevenness is difficult to be formed in the portions that are difficult to soften. Therefore, unevenness is likely to be formed in the softened portions of the transparent thermoplastic resin layer 6 and the surface protection layer 7, that is, the portions that overlap with the gloss matte pattern portion 3 in plan view. Therefore, the embossed portion 7a having an uneven shape that is in sync with the gloss matte developing handle 3 is likely to be formed only in the position where the transparent thermoplastic resin layer 6 and the surface protection layer 7 overlap with the gloss matte developing handle 3 in plan view. Become.

As a result, the embossed portion 7a can be formed at a position that is synchronized with the pattern layer 5. In other words, the embossed portion 7a that is synchronized with the pattern layer 5 can be easily created without performing a highly accurate positioning operation. .
Note that the timing of stamping the transparent thermoplastic resin layer 6 and the surface protection layer 7 with an embossing plate after infrared irradiation is not limited to immediately after infrared irradiation, but also the timing of stamping the transparent thermoplastic resin layer 6 and the surface protection layer 7 with the embossing plate is not limited to immediately after infrared irradiation. Any timing is sufficient as long as it is possible to selectively form an uneven shape in the portion softened by infrared irradiation by stamping the surface of the layer 7.
Further, other steps may be included between the step of creating the surface protective layer 7 and the step of performing infrared irradiation. 7 is formed.

[Effects of this embodiment]
(1) According to the method for manufacturing the decorative sheet 1 according to the present embodiment, the laminate in which each layer is laminated is irradiated with infrared rays, and then the embossing plate is pressed, so that the pattern for producing gloss matte can be seen in plan view. Strong embossing can be performed on the part that overlaps part 3. In other words, the embossed portion can be easily formed at a desired position without having to position the embossing plate with high accuracy. As a result, a decorative sheet with excellent design can be easily obtained.

(2) In addition, since the gloss-matte-producing pattern 3 is provided below the colored thermoplastic resin layer 2, when the decorative sheet 1 is viewed from the surface protection layer 7 side, the gloss-matte-producing pattern 3 The visibility of 3 becomes low. As a result, although a high-density black ink with infrared absorption properties is used for the pattern 3 for producing gloss matte, when the decorative sheet 1 is viewed from the surface protection layer 7 side, the pattern 3 for producing gloss matte is Visual recognition can be suppressed. Therefore, even if a dark color pattern is not used as the pattern layer 5, it is possible to suppress the gloss matte expression pattern portion 3 containing black ink from being visible, and as a result, a light color pattern is adopted as the pattern layer 5. This also makes it possible to suppress restrictions on pattern expression due to the pattern layer 5, which is caused by providing the pattern section 3 for gloss matte expression.

Further, on a pattern layer 8a consisting of a pattern part 3 for producing a gloss matte using high-density black ink having infrared absorption characteristics, a colored thermoplastic resin layer 2 and a pattern layer 5 are formed, and further a transparent thermoplastic resin layer 6 is formed. and a surface protective layer 7 are laminated, and an embossed portion 7a is formed at a position overlapping with the pattern 3 for producing gloss matte in a plan view of the surface protective layer 7, so that the pattern 3 for producing gloss matte using black ink is The pattern part 3 for producing gloss matte, which is useful in the manufacturing process of the decorative sheet 1, can reduce the visibility of the pattern layer 5 and suppress the influence on the appearance of the decorative sheet 1. It is possible to obtain a decorative sheet 1 with a high design quality in which the portions 7a are aligned.

(3) Furthermore, since the pattern part 3 for producing gloss matte is provided in synchronization with the pattern of the pattern layer 5, it is possible to form an uneven part in synchronization with the pattern of the pattern layer 5, that is, in synchronization with the pattern. A glossy matte effect can be easily achieved.
(4) Furthermore, since the gloss matte is expressed by providing the unevenness, it is possible to suppress the pattern from coming off of the gloss mat. Therefore, for example, it is possible to perform synchronized gloss matte expression on flooring materials and the like.

[Modified example]
(1) In the above embodiment, a material containing black ink is used as the gloss matte developing handle 3, and the transparent thermoplastic resin layer 6 and the surface protection layer 7 are partially softened by infrared irradiation. Although explained above, it is not limited to this. By using a material containing an arbitrary ink made of a component that has light absorption property for light of a predetermined wavelength as the material of the pattern part 3 for producing gloss matte, and using a light source that irradiates light of the predetermined wavelength, transparent thermal The plastic resin layer 6 and the surface protection layer 7 may be partially softened.

(Example 1)
On one side of the colored thermoplastic resin layer 2 made of a PBT layer with a thickness of 50 μm, a pattern layer 5 made of a urethane printing ink, a transparent thermoplastic resin layer 6 made of a PP layer with a thickness of 38 μm, and an acrylic resin. A surface protective layer 7 containing the composition as a main component was laminated in this order. Further, on the other surface of the colored thermoplastic resin layer 2, a black ink made of urethane printing ink is pattern-printed to form a pattern part 3 for producing gloss matte, and the colored thermoplastic resin layer 2 includes the pattern part 3 for producing gloss matte. A primer layer 8 was formed on the plastic resin layer 2 to obtain a laminate.

At this time, a plurality of laminates having gloss matte-producing handles 3 having different image density levels were created by solid printing black ink using printing plates with different image density levels. The image density levels were 0%, 20%, 40%, 60%, 70%, 80%, and 90%. Note that the image density level here means the ratio of the area coated with ink in a certain area.
The transparent thermoplastic resin layer 6 was formed by laminating on the pattern layer 5. After forming the primer layer 8, this laminate was heated with an infrared heater, and then an embossing roll was pressed against the surface protection layer 7 to form the embossed portions 7a, thereby obtaining the decorative sheet shown in FIG. 1. At this time, the temperature of the laminate was 125° C., the concavo-convex pattern was matte with a height of 60 μm, and the nip pressure was 850 kg.

(Comparative example 1)
Comparative Example 1 was the same as Example 1 except that black ink made of urethane printing ink was pattern printed between the pattern layer 5 and the transparent thermoplastic resin layer 6 to form the pattern part 3 for producing gloss matte. I created a makeup sheet. The image density levels were 60%, 70%, 80%, and 90%.
(Comparative example 2)
As Comparative Example 2, an original fabric consisting of a colored thermoplastic resin layer 2 consisting of a PBT layer with a thickness of 50 μm was created.

〔evaluation〕
The infrared transmittance was measured for each of the decorative sheets of Example 1 and Comparative Example 1 having different image density levels, and for the original sheet of Comparative Example 2. Infrared transmittance was measured by the method described below.
The color difference, glossiness, and difference in glossiness were obtained for each of the decorative sheet for each image density level of Example 1, the decorative sheet for each image density level of Comparative Example 1, and the original fabric of Comparative Example 2. As the acquisition method, the method described below was used. The obtained results are shown in Table 1. The numerical values shown in Table 1 are the average values of the results measured for each image density level.

[Infrared transmittance measurement]
The infrared transmittance was measured for each of the decorative sheets of Example 1 and Comparative Example 1, which had different image density levels, and of the original sheet of Comparative Example 2. Specifically, infrared transmittance at a wavelength of 2000 nm was measured using an ultraviolet/visible spectrometer UV3600 manufactured by SHIMADZU.
[Color difference measurement]
Color differences were measured for each decorative sheet of Example 1 and each decorative sheet of Comparative Example 1, which had different image density levels, and for the original fabric of Comparative Example 2. Specifically, the color difference ΔE with respect to the standard plate was calculated using a color difference meter CR-400 manufactured by Konica Minolta Japan, Inc.

[Glossiness measurement]
After embossing each decorative sheet of Example 1 and each decorative sheet of Comparative Example 1 with different image density levels and the original fabric of Comparative Example 2, a surface protective layer was applied directly above the pattern for producing gloss matte. Regarding No. 7, specular gloss was measured at an incident angle of 85° using micro-TRI-gloss manufactured by BYK.
[Difference in gloss]
For each decorative sheet of Example 1 and each decorative sheet of Comparative Example 1 with different image density levels, and the original fabric of Comparative Example 2, the portion where the pattern for producing gloss matte is not formed after embossing. The specular gloss of the surface protective layer directly above was measured in the same manner as in the gloss measurement, and the difference between the gloss and the gloss of the surface protective layer directly above the gloss matte pattern was determined. The presence or absence of gloss matte development was confirmed by the difference in glossiness.

〔result〕
Although the decorative sheet of Example 1 has some difference in glossiness, it suppresses the effect on color difference and can obtain the same glossiness as the decorative sheet of Comparative Example 1, and is different from the original sheet of Comparative Example 2. The glossiness difference was around 5, which satisfied the glossiness difference of 3, which generally makes it possible to confirm a gloss-matte expression, so it was confirmed that a gloss-matte expression could be obtained. Furthermore, compared to the decorative sheet of Comparative Example 1, the decorative sheet of Example 1 can suppress the color difference from the standard plate, thereby suppressing the visibility of the pattern for producing gloss matte. .
That is, by providing the gloss-matte expression pattern part 3 on the back side of the colored thermoplastic resin layer, it is possible to obtain the same difference in glossiness as the decorative sheet of Comparative Example 1 without significantly affecting the color difference. It was confirmed that decorative sheet 1 could be obtained. In other words, it was confirmed that a decorative sheet capable of producing the same gloss-matte appearance as the decorative sheet of Comparative Example 1 could be obtained.

1 Decorative sheet 2 Colored thermoplastic resin layer 3 Pattern for gloss matte expression 5 Pattern layer 6 Transparent thermoplastic resin layer 7 Surface protection layer 7a Embossed portion 8 Primer layer 8a Pattern layer

Claims (3)

A method for manufacturing a decorative sheet having an embossed shape that matches a pattern,
a step of laminating a pattern layer, a transparent resin layer, and a surface protection layer in this order on one side of the colored resin layer;
forming a pattern layer on the other surface of the colored resin layer that synchronizes with the pattern using a predetermined material that is more absorbent than the colored resin layer for light of a predetermined wavelength;
irradiating the irradiation light with the power of the light of the predetermined wavelength stronger than the power of the light of other wavelengths;
After the step of irradiating the irradiation light, pressing the surface protective layer with an embossing plate for forming the embossed shape;
A method for producing a decorative sheet, comprising: 2. The method of manufacturing a decorative sheet according to claim 1, wherein the predetermined material is formed including black ink containing carbon black, and the irradiation light is infrared rays. A decorative sheet having a pattern layer,
A pattern layer, a transparent resin layer, and a surface protection layer are laminated in order on one side of the colored resin layer,
a pattern layer laminated on the other surface of the colored resin layer, in which a predetermined material having a light absorbency for light of a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern of the pattern layer; ,
Equipped with
A decorative sheet characterized in that an embossed portion is formed in a position of the surface protective layer that overlaps a portion formed of the predetermined material in plan view.

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